Free cooling refrigeration system

ABSTRACT

A refrigeration system includes a chiller with an integrated free cooling system and refrigeration system. In certain embodiments, the chiller may be a single package unit with all equipment housed within the same support frame. The chiller may generally include three modes of operation: a first mode that employs free cooling, a second mode that employs free cooling and implements a refrigeration cycle, and a third mode that uses the free cooling system to remove heat from the refrigeration system. A heat exchanger may be shared between the free cooling system and the refrigeration system to transfer heat from the refrigeration system to the free cooling system.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority from and the benefit of U.S.Provisional Application Ser. No. 61/162,825, entitled “Free CoolingRefrigeration System”, filed Mar. 24, 2009, which is hereby incorporatedby reference.

BACKGROUND

The invention relates generally to free cooling refrigeration systems.

Many applications exist for refrigeration systems including residential,commercial, and industrial applications. For example, a commercialrefrigeration system may be used to cool an enclosed space such as adata center, laboratory, supermarket, or freezer. Very generally,refrigeration systems may include circulating a fluid through a closedloop between an evaporator where the fluid absorbs heat and a condenserwhere the fluid releases heat. The fluid flowing within the closed loopis generally formulated to undergo phase changes within the normaloperating temperatures and pressures of the system so that considerablequantities of heat can be exchanged by virtue of the latent heat ofvaporization of the fluid.

Refrigeration systems may operate with a free cooling system or loopwhen ambient temperatures are low. The free cooling system may exploitthe low temperature of the ambient air to provide cooling without theneed for an additional energy input from, for example, a compressor, athermoelectric device, or a heat source. Typically, free cooling systemsmay employ a separate heat exchanger or portion of a heat exchanger coilwhen operating in a free cooling mode. When free cooling is not desired,or feasible, the separate heat exchanger or coil portion may not beutilized.

SUMMARY

The present invention relates to a refrigeration system with a freecooling system configured to exchange heat between a cooling fluid andambient air. The refrigeration system also includes a heat exchangerconfigured to receive refrigerant and to transfer heat from therefrigerant to the cooling fluid.

The present invention also relates to a refrigeration system with avapor-compression refrigeration system that includes an evaporatorconfigured to remove heat from a cooling fluid circulating through acooling loop, a free cooling system configured to circulate the coolingfluid through a first circuit to exchange heat between the cooling fluidand ambient air without implementing a vapor-compression cycle, and asecond circuit disposed in the free cooling system and configured tocirculate an isolated portion of the cooling fluid through a heatexchanger common to the vapor-compression refrigeration system and thefree cooling system.

The present invention further relates to a method for operating arefrigeration system that includes operating a vapor-compressionrefrigeration system to remove heat from a cooling fluid and circulatingan isolated portion of the cooling fluid within a free cooling system toremove heat from the vapor-compression refrigeration system.

DRAWINGS

FIG. 1 is perspective view of an exemplary commercial or industrialenvironment that employs a free cooling refrigeration system.

FIG. 2 is a diagrammatical overview of an exemplary free coolingrefrigeration system.

FIG. 3 is an elevational view of the free cooling refrigeration systemshown in FIG. 2.

FIG. 4 is an elevational view of an exemplary free cooling refrigerationsystem employing air-to-liquid heat exchangers that share a fan.

FIG. 5 is an elevational view of an exemplary free cooling refrigerationsystem employing liquid-to air heat exchangers in a multi-slabconfiguration.

FIG. 6 is a diagrammatical overview of an exemplary free coolingrefrigeration system employing a heat recovery loop.

FIG. 7 is a diagrammatical overview of another exemplary free coolingrefrigeration system employing a heat recovery loop.

FIG. 8 is a diagrammatical overview of an exemplary free coolingrefrigeration system showing an alternate location for the common heatexchanger.

FIG. 9 is a diagrammatical overview of an exemplary free coolingrefrigeration system employing two common heat exchangers.

FIG. 10 is a diagrammatical overview of an exemplary free coolingrefrigeration system illustrating another pump and valve configuration.

FIG. 11 is a diagrammatical overview of an exemplary free coolingrefrigeration system illustrating yet another pump and valveconfiguration.

DETAILED DESCRIPTION

FIG. 1 depicts an exemplary application for a refrigeration system. Suchsystems, in general, may be applied in a range of settings, both withinthe heating, ventilating, air conditioning, and refrigeration (HVAC&R)field and outside of that field. The refrigeration systems may providecooling to data centers, electrical devices, freezers, coolers, or otherenvironments through vapor-compression refrigeration, absorptionrefrigeration, or thermoelectric cooling. In presently contemplatedapplications, however, refrigeration systems may be used in residential,commercial, light industrial, industrial, and in any other applicationfor heating or cooling a volume or enclosure, such as a residence,building, structure, and so forth. Moreover, the refrigeration systemsmay be used in industrial applications, where appropriate, for basicrefrigeration and heating of various fluids.

FIG. 1 illustrates an exemplary application, in this case an HVAC&Rsystem for building environmental management that may employ heatexchangers. A building 10 is cooled by a system that includes a chiller12 and a boiler 14. As shown, chiller 12 is disposed on the roof ofbuilding 10 and boiler 14 is located in the basement; however, thechiller and boiler may be located in other equipment rooms or areas nextto the building. Chiller 12 is an air cooled or water cooled device thatimplements a refrigeration cycle to cool water. Chiller 12 is housedwithin a single structure that includes a refrigeration circuit, a freecooling system, and associated equipment such as pumps, valves, andpiping. For example, chiller 12 may be single package rooftop unit thatincorporates a free cooling system. Boiler 14 is a closed vessel thatincludes a furnace to heat water. The water from chiller 12 and boiler14 is circulated through building 10 by water conduits 16. Waterconduits 16 are routed to air handlers 18, located on individual floorsand within sections of building 10.

Air handlers 18 are coupled to ductwork 20 that is adapted to distributeair between the air handlers and may receive air from an outside intake(not shown). Air handlers 18 include heat exchangers that circulate coldwater from chiller 12 and hot water from boiler 14 to provide heated orcooled air. Fans, within air handlers 18, draw air through the heatexchangers and direct the conditioned air to environments withinbuilding 10, such as rooms, apartments or offices, to maintain theenvironments at a designated temperature. A control device, shown hereas including a thermostat 22, may be used to designate the temperatureof the conditioned air. Control device 22 also may be used to controlthe flow of air through and from air handlers 18. Other devices may, ofcourse, be included in the system, such as control valves that regulatethe flow of water and pressure and/or temperature transducers orswitches that sense the temperatures and pressures of the water, theair, and so forth. Moreover, control devices may include computersystems that are integrated with or separate from other building controlor monitoring systems, and even systems that are remote from thebuilding.

FIG. 2 schematically illustrates chiller 12, which incorporates a freecooling system. As noted above with respect to FIG. 1, chiller 12 ishoused within a single structure and may be located outside of abuilding or environment, for example on a roof top. Chiller 12 includesa cooling fluid loop 24 that circulates a cooling fluid, such as chilledwater, an ethylene glycol-water solution, brine, or the like, to acooling load, such as a building, piece of equipment, or environment.For example, cooling fluid loop 24 may circulate the cooling fluid towater conduits 16 shown in FIG. 1. Chiller 12 also includes arefrigeration system loop 26 that is in fluid communication with coolingfluid loop 24 to remove heat from the cooling fluid circulating withinthe cooling fluid loop 24. Chiller 12 further includes a free coolingsystem 28 that exploits the low temperature of ambient air in order tocool the cooling fluid circulating within cooling fluid loop 24. Incertain embodiments, the cooling fluid may circulate within the coolingfluid loop 24 to a cooling load, such as a research laboratory, computerroom, office building, hospital, molding and extrusion plant, foodprocessing plant, industrial facility, machine, or any otherenvironments or devices in need of cooling. Free cooling system 28includes two circuits 30 and 32 that are each configured to direct thecooling fluid to different portions of free cooling system 28. Chiller12 also includes a control device 33 that enables chiller 12 to cool thefluid within cooling fluid loop 24 to a prescribed temperature orprescribed range of temperatures.

Chiller 12 may operate in three different modes of operation dependingon the requirements of the cooling load and the temperature of theambient air. When the outside air temperature is low, for example,during winter in northern climates, the chiller 12 may operate in a freecooling mode that directs the cooling fluid through free cooling system28 before returning the fluid to the cooling load. In this mode ofoperation, the cooling fluid may be cooled by low temperature outdoorair as the cooling fluid circulates through circuit 30 of free coolingsystem 28. If additional cooling capacity is desired or needed, chiller12 may operate in a second mode of operation that employs mechanicalcooling, in addition to the free cooling provided by free cooling system28. During mechanical cooling, refrigeration system 26 may implement avapor-compression cycle to provide additional cooling for the coolingfluid. For example, in this mode of operation, the cooling fluid mayfirst be cooled by low temperature outdoor air as the cooling fluidcirculates through circuit 30 of free cooling system 28. After exitingfree cooling system 28, the cooling fluid may undergo further cooling bytransferring heat to a refrigerant flowing within refrigeration system26. To provide even more cooling capacity, chiller 12 may operate in athird mode of operation that employs refrigeration system 26 and thesecond circuit 32 of the free cooling system 28 to supplement cooling ofrefrigerant in refrigeration system 26. In this mode of operation, thecooling fluid that circulates to the cooling load may be cooled byrefrigerant flowing within refrigeration system 26. Free cooling system28 may be used to cool the refrigerant flowing within refrigerationsystem 26. Specifically, a portion of the cooling fluid may be separatedfrom cooling fluid loop 24 and circulated within circuit 32 of freecooling system 28. The cooling fluid within circuit 32 may absorb heatfrom the refrigerant flowing within refrigeration system 26 to provideadditional cooling capacity.

Regardless of the mode of operation, chiller 12 may function to cool thecooling fluid circulating to and from a cooling load, such as abuilding. The cooling fluid may enter chiller 12 through a return line34 that is in fluid communication with the cooling load. A pump 36circulates the cooling fluid through cooling fluid loop 24 and directsthe cooling fluid to a connection point 37 that fluidly connects freecooling system 28 to cooling fluid loop 24. A valve 38 may be located atconnection point 37 and may direct the cooling fluid to free coolingsystem 28. In certain embodiments, valve 38 may be a three-way servocontrolled valve configured to direct cooling fluid through the freecooling system 28 in one position and to bypass the free cooling system28 in another position. However, in other embodiments, valve 38 may be aball valve, rotor valve or the like controlled by electromechanicalactuators, pneumatic actuators, hydraulic actuators, or other suitablecontrols.

The chiller 12 may operate in the first mode, or free cooling mode, ofoperation when the ambient air temperature is sufficiently low enough toprovide free cooling. For example, chiller 12 may operate in the freecooling mode during the winter when outside temperatures are belowapproximately 12-15 degrees Celsius. However, in other embodiments, thecooling mode determination may depend on a variety of factors such asthe cooling requirement of the cooling load, the outside temperatureand/or humidity, the type of cooling fluid, and the cooling capacity ofthe chiller 12 among other things. In the first mode, valve 38 maydirect the cooling fluid through the first circuit 30 of free coolingsystem 28. Within circuit 30, a pump 39 may circulate the cooling fluidthrough free cooling system 28. The pump may be any suitable type ofpump such as a positive displacement pump, centrifugal pump, or thelike. From pump 39, the cooling fluid may flow through a connectionpoint 40 that intersects with the second circuit 32 of free coolingsystem 28. From connection point 40, the cooling fluid may enter anair-to-liquid heat exchanger 42. Heat exchanger 42 may include a fin andtube heat exchanger, brazed aluminum multichannel heat exchanger, orother suitable heat exchanger. The cooling fluid may flow through tubesof heat exchanger 42 to transfer heat to the ambient air. A fan 44,which is driven by a motor 46, draws air across heat exchanger 42. Asthe air flows across heat exchanger 42, heat may transfer from thecooling fluid to the air, thereby cooling the cooling fluid, andproducing heated air. Therefore, the temperature of the cooling fluidexiting heat exchanger 42 may be less than the temperature of thecooling fluid entering heat exchanger 42.

Upon exiting heat exchanger 42, the cooling fluid may flow to aconnection point 48 that connects first circuit 30 with the secondcircuit 32. However, the cooling fluid may not flow through the secondcircuit in this mode of operation. From connection point 48, the coolingfluid may flow through a connection point 52 to return to cooling fluidloop 24. The cooling fluid may then circulate within cooling loop 24 toan evaporator 54. In this first mode of operation, evaporator 54 mayfunction as a reservoir without providing any substantial evaporatingcooling of the cooling fluid. From evaporator 54, the cooling fluid mayreturn to the cooling load through a supply line 56. Supply line 56 maycirculate the cooling fluid to the cooling load where the cooling fluidmay be heated by the cooling load. For example, the cooling fluid mayabsorb heat from air within a building or from a fluid flowing within adevice. After receiving heat from the cooling load, the cooling fluidmay enter chiller 12 through return line 34 where the cooling cycle maybegin again.

Chiller 12 may operate in a second mode of operation when the outsideair temperature has increased and/or when the outside air temperature isnot cool enough to provide efficient cooling to the cooling load. In thesecond mode of operation, refrigeration system 26 may implement avapor-compression cycle, or other type of cooling cycle, such asabsorption or a thermoelectric cycle, to provide additional cooling forthe cooling load. The cooling fluid may flow through free cooling system28 as previously described with respect to the first mode of operation.As the cooling fluid flows through free cooling system 28, the coolingfluid may transfer heat to the ambient air through heat exchanger 42.The cooling fluid, after being cooled by the ambient air, may flowthrough connection point 52 and re-enter fluid cooling loop 24.

The cooling fluid may then flow into evaporator 56 where it may becooled by refrigerant from refrigeration system 26. Evaporator 54 may bea plate heat exchanger, a shell and tube heat exchanger, a plate andshell heat exchanger, or any other suitable type of heat exchanger.Evaporator 54 may circulate refrigerant flowing within a closed loop ofrefrigeration system 26. The refrigerant may be any fluid that absorbsand extracts heat. For example, the refrigerant may be ahydrofluorocarbon (HFC) based R-410A, R-407C, or R-134a, or it may becarbon dioxide (R-744A) or ammonia (R-717). As the refrigerant flowsthrough evaporator 54, the refrigerant may absorb heat from the coolingfluid flowing within evaporator 54 to cool the cooling fluid before thecooling fluid returns to the cooling load through supply line 56.

Within refrigeration system 26, the refrigerant may circulate through aclosed loop including a compressor 58, a heat exchanger 60, a condenser62, and an expansion device 63. In operation, the refrigerant may exitevaporator 54 as a low pressure and temperature vapor. Compressor 58 mayreduce the volume available for the refrigerant vapor, consequently,increasing the pressure and temperature of the vapor refrigerant. Thecompressor may be any suitable compressor, such as a screw compressor,reciprocating compressor, rotary compressor, swing link compressor,scroll compressor, or centrifugal compressor. The compressor 58 may bedriven by a motor that receives power from a variable speed drive or adirect AC or DC power source. From compressor 58, the high pressure andtemperature vapor may flow through a heat exchanger 60 that may functionas a receiver in this second mode of operation.

From heat exchanger 60, the high pressure and temperature vapor may flowto condenser 62. A fan 64, which is driven by a motor 66, draws airacross the tubes of condenser 62. The fan may push or pull air acrossthe tubes. As the air flow across the tubes, heat transfers from therefrigerant vapor to the air, causing the refrigerant vapor to condenseinto a liquid and heating the ambient air. The liquid refrigerant thenenters an expansion device 63 where the refrigerant expands to become alow pressure and temperature liquid-vapor mixture. Typically, expansiondevice 63 will be a thermal expansion valve (TXV); however, according toother exemplary embodiments, the expansion device may be anelectromechanical valve, an orifice, or a capillary tube. From expansiondevice 63, the liquid refrigerant may enter evaporator 54 where theprocess may begin again, and the refrigerant may absorb heat from thecooling fluid flowing through evaporator 54.

Refrigeration system 26 generally includes a high-pressure side and alow-pressure side. The high-pressure side includes the section ofrefrigeration system 26 that circulates the higher-pressure refrigerant(i.e., after compression and before expansion). Specifically, thehigh-pressure side includes the section that circulates the refrigerantfrom compressor 58 through heat exchanger 60, condenser 62, andexpansion device 63. The low-pressure side includes the section ofrefrigeration system 26 that circulates the lower-pressure refrigerant(i.e., after expansion and before compression). Specifically, thelow-pressure side includes the portion of refrigeration system 26 thatcirculates refrigerant from expansion valve 63 through evaporator 54into compressor 58.

As described above in the second mode of operation, the cooling fluidwithin cooling loop 24 may be cooled by both the free cooling system 28and the refrigeration system 26. Specifically, the free cooling system28 may circulate the cooling fluid through the first circuit 30 totransfer heat from the cooling fluid to ambient air throughair-to-liquid heat exchanger 42. After the cooling fluid has been cooledby the ambient air, the cooling fluid may then flow through evaporator54 where the refrigeration system 26 may further remove heat from thecooling fluid by absorbing heat from the cooling fluid into refrigerantflowing within evaporator 54. In this manner, both free cooling system28 and the refrigeration system 26 may be used to provide coolingcapacity during this second mode of operation.

When even further refrigeration or cooling capacity is desired, chiller12 may operate in a third mode of operation employing supplementalcooling. In this mode, the cooling fluid may enter chiller 12 throughreturn line 34, flow through pump 36, and through valve 38 at connectionpoint 37. From valve 38, the cooling fluid may flow directly toconnection point 52, bypassing free cooling system 28. From connectionpoint 52, the cooling fluid may flow through evaporator 54 where it maybe cooled by the refrigerant flowing through the refrigeration system26. In this third mode of operation, the refrigeration system 26 mayreceive supplemental cooling from the cooling fluid flowing through heatexchanger 60.

When chiller 12 enters the third mode of operation, a portion of coolingfluid from cooling fluid loop 24 may be isolated, or partially isolated,within the second circuit 32 of free cooling system 28. For example,pump 39 may be disengaged and pump 68 may be enabled to draw coolingfluid through the second circuit 32. The second circuit 32 may circulatecooling fluid from connection point 40 through air-to-liquid heatexchanger 42, pump 68, check valve 70, and heat exchanger 60. As thecooling fluid flows through heat exchanger 60, the cooling fluid mayabsorb heat from the compressed refrigerant exiting compressor 58 andflowing through heat exchanger 60. Heat exchanger 60 may include a plateheat exchanger, a shell and tube heat exchanger, a plate and shell heatexchanger, or any other suitable type of heat exchanger. In certainembodiments, heat exchanger 60 may function to desuperheat thecompressed refrigerant before it enters condenser 62. By transferringheat from the refrigerant to the cooling fluid within the second circuit32 of free cooling system 28, heat exchanger 60 may provide additionalcooling capacity for refrigeration system 26.

As the cooling fluid flows through heat exchanger 60, the cooling fluidmay absorb heat from the refrigerant, thereby cooling the refrigerant.The heated cooling fluid may exit heat exchanger 60 and flow throughsecond circuit 32 to connection point 40. From connection point 40, theheated cooling fluid may flow through air-to-liquid heat exchanger 42where the cooling fluid may be cooled by the ambient air directedthrough heat exchanger 42 by fan 44. The cooling fluid may then exitheat exchanger 42 and flow through a pump 68 and valve 70. Pump 68 mayinclude any suitable type of pump configured to circulate the coolingfluid through second circuit 32. Valve 70 may include a check valve thatprevents the backward flow of cooling fluid through pump 68. However, inother embodiments, pump 68 may include a positive displacement pump withan integrated valve feature that prevents backwards flow. In thisembodiment, valve 70 may be eliminated. Further, in other embodiments,valve 70 may be a manually actuated valve, solenoid valve, gate valve,or other suitable type of valve. From valve 70, the cooling fluid mayenter heat exchanger 60 where it may again absorb heat from therefrigerant circulating within refrigeration system 26.

Accordingly, during the third mode of operation, heat exchanger 60 maybe used to transfer heat from refrigeration system 26 to free coolingsystem 28. Free cooling system 28 may circulate the heated cooling fluidfrom heat exchanger 60 to air-to-liquid heat exchanger 42 to expel theheat into the environment. In this manner, air-to-liquid heat exchanger42 may be used by chiller 12 to remove heat from the system even whenthe system is not operating in a free cooling mode. For example, secondcircuit 32 may be used to remove heat from refrigeration system 26 evenwhen environmental air temperatures may be higher then the chilled watersupply temperature. Specifically, even though the ambient airtemperature may be high, for example above 70 degrees Fahrenheit, theambient air temperature still may be lower than the temperature of thehigh pressure and temperature refrigerant flowing within therefrigeration system 26. This temperature difference may enableair-to-liquid heat exchanger 42 to transfer heat from refrigerationsystem 26 to the environment, thereby increasing the cooling capacity ofrefrigeration system 26.

The operation of chiller 12 may be governed by control devices 33, whichinclude control circuitry 72 and temperature sensors 74 and 76.Circuitry 72 may be coupled to valve 38 and pumps 39 and 68, which drivethe first and second circuits 30 and 32, respectively. Control circuitry72 may use information received from sensors 74 and 76 to determine whento operate pumps 39 and 68. In some applications, control circuit 72also may be coupled to motors 46 and 66, which drive fans 44 and 64,respectively. In some applications, control circuit 72 may include localor remote command devices, computer systems and processors, and/ormechanical, electrical, and electromechanical devices that manually orautomatically set a temperature related signal that a system receives.

Control circuitry 72 may be configured to switch chiller 12 between thefirst, second, and third modes of operation based on input received fromtemperature sensors 74 and 76. Temperature sensor 74 may sense thetemperature of the ambient outside air and temperature sensor 76 maysense the temperature of the cooling fluid returning from the coolingload. For example, temperature sensor 76 may be disposed within coolingloop 24. In certain embodiments, when the ambient air temperature sensedby sensor 74 is below the cooling fluid temperature sensed bytemperature sensor 76, control circuitry 72 may set chiller 12 tooperate in a first mode of operation that employs free cooling bycirculating the cooling fluid through the first circuit 30 of freecooling system 28. For example, control circuitry 72 may set valve 38 todirect cooling fluid through free cooling system 28 and may disable pump68 and compressor 58. Control circuitry 72 may operate chiller 12 in thefirst mode of operation until the temperature of the ambient air reachesa specified value or is a certain amount above the temperature of thecooling fluid. Control circuitry 72 may then set chiller 12 to operatein the second mode of operation that employs refrigeration system 26, inaddition to circulating the cooling fluid through the first circuit 30of cooling system 28. In certain embodiments, control circuitry 72 mayenable compressor 58 and motor 66 to circulate refrigerant throughrefrigeration system 26. Control circuitry 72 may operate chiller 12 inthe second mode of operation until the ambient air temperature reachesanother specified value or amount above the cooling fluid temperature oruntil the cooling fluid temperature rises above a certain threshold.Control circuitry 72 may then switch chiller 12 to the third mode ofoperation that employs the second circuit 32 of free cooling system 28to remove heat from refrigeration system 26. For example, controlcircuitry 72 may then disable pump 39 and enable pump 68 to circulate aportion of the cooling fluid through the second circuit 32.

The control circuitry may be based on various types of control logicthat uses input from temperature sensors 74 and 76. Control circuitry 72also may control other valves and pumps disposed within therefrigeration system. Further, additional inputs such as flow rates,pressures, and other temperature may be used in controlling theoperation of chiller 12. For example, other devices may be included inchiller 12, such as additional pressure and/or temperature transducersor switches that sense temperatures and pressures of the refrigerant andcooling fluid, the heat exchangers, the inlet and outlet air, and soforth. Further, the examples provided for determining the mode ofoperation are not intended to be limiting. Other values and set pointsbased on a variety of factors such as system capacity, cooling load, andthe like may be used to switch chiller 12 between the first, second, andthird modes of operation.

The pump and valve configurations included in FIG. 2 are shown by way ofexample only and are not intended to be limiting. For example, thelocations, numbers, and types of pumps and valves may vary. In oneexample, pump 39 may be eliminated and pump 36 may circulate the coolingfluid through free cooling system 28. Pump 39 also may be locatedanywhere within first circuit 30, and pump 68 may be located anywherewithin second circuit 32. In certain embodiments, valve 38 may beeliminated, if, for example, pump 39 is equipped with a positive shutofffeature. In another example, pumps 68 and 39 may be equipped withpositive shutoff features and valves 70 and 38 may be eliminated. In yetanother example, valve 38 may be located at connection point 40, 48, or52. Further valve 38 may be replaced by two two-way valves. For example,in one embodiment, a first two-way valve may be located betweenconnection points 38 and 40 or between connection points 48 and 52 and asecond two-way valve may be located between connection points 38 and 52.Of course, many other pump and valve configurations may be envisaged andemployed in chiller 12.

FIG. 3 is an elevational view of chiller 12. Chiller 12 may be housedcompletely within a single cabinet or support frame 78. In certainembodiments, support frame 78 may be a box-shaped structure composed ofmetal panels. Control circuit 72 may be mounted on support frame 78 thathouses equipment 80, such as pumps, compressors, heat exchangers,valves, piping, and the like, included within chiller 12. In certainembodiments, the air-to-liquid heat exchangers 42 and 62 may be disposedin adjacent V-shaped configurations within support frame 78. Each heatexchanger 42 and 62 may include two heat exchanger slabs disposedbeneath fans 44 and 64. However, in other embodiments, the number ofslabs within each heat exchanger may vary. Further, additional heatexchanger slabs may be connected in series to provide additional coolingcapacity. In certain embodiments, the free cooling system heat exchanger42 may be disposed towards the outside of the cabinet 78 such that theheat exchanger 42 may receive the coolest environmental air.

FIG. 4 shows an alternate heat exchanger configuration for chiller 12.In this configuration, heat exchangers 42 and 62 share a common fan 82.The heat exchangers may be disposed in a V-shaped configuration withair-to-liquid heat exchanger 42 on one side and condenser 62 on theother side. Shared fan 82 may draw air over both heat exchangers 42 and62. In certain embodiments, the use of a common fan configuration mayreduce equipment costs.

FIG. 5 illustrates another heat exchanger configuration, whereair-to-liquid heat exchanger 42 and condenser 62 are disposed in amulti-slab configuration to share common fan 82. In this configuration,the slabs of each heat exchanger 42 and 62 are disposed adjacent to eachother. However, the configurations illustrated in FIGS. 3 through 5 areprovided by way of example only and are not intended to be limiting. Forexample, depending on factors such as system capacity, cooling loadrequirements, piping configurations, climate temperatures, and averagehumidity, among other things, the number of slabs within heat exchangers42 and 62 may vary. Further, multiple slabs may be connected in seriesto provide additional cooling capacity. Moreover, the heat exchangersmay include various multi-slab configurations, additional V-shapedconfigurations, and additional heat exchangers.

FIG. 6 illustrates another exemplary chiller 84 that includes freecooling system 28, cooling loop 24, and refrigeration system 26. Chiller84 also includes a heat recovery loop 86 disposed within the secondcircuit 32 of free cooling system 28. The heat recovery loop 86 includesa closed loop that circulates through a heat exchanger 88 located withinsecond circuit 32. Heat exchanger 88 allows heat to be transferred fromthe cooling fluid flowing within second circuit 32 to a device 89 influid communication with heat recovery loop 86. Device 89 may be anydevice that utilizes an input of heat. For example, device 89 may be awater heater, space heater, or other device. A pump 90 circulates afluid, such as water or any suitable refrigerant, within closed loop 86.As the fluid flows through device 89, for example, within a coildisposed in device 89, the fluid may transfer heat to an interior volumeof device 89. In certain embodiments, pump 90 may be controlled bycontrol circuitry 72 and enabled to provide heat to device 89 whenchiller 84 is operating in the third mode of operation. Further, incertain embodiments, device 89 may be housed outside of chiller 84 andconnected to the chiller via piping. Moreover, additional equipment,such as bypass valve, pumps, and the like, may be included in thechiller 84.

FIG. 7 illustrates another chiller 91 that includes an alternate heatrecovery loop 92. Heat recovery loop 92 is in fluid communication withsecond circuit 32 and includes a three-way valve 93 configured to directcooling fluid exiting heat exchanger 60 through heat recovery loop 92.The cooling fluid may be circulated through valve 93 to a device 94 totransfer heat from the cooling fluid to device 94. Device 94 may be anydevice that utilizes input of heat, such as a water heater, spaceheater, or other suitable device. In certain embodiments, controlcircuitry 72 may be connected to valve 93 to govern operation of valve93. When heat is required within device 94, the valve 93 may be set todirect fluid to heat recovery loop 92. However, when no heat input isdesired, the valve 93 may be set to bypass heat recovery loop 92. Incertain embodiments, heat recovery loop 92 may be used to provide reheatfor humidity control within a system. For example, device 94 may be anair duct within a building where air is cooled below a set point toreduce humidity. The cooled air may be reheated by heat recovery loop92. In other embodiments, device 94 may be a water heater or a spaceheater. Moreover, additional equipment, such as bypass valve, pumps, andthe like, may be included in the chiller 91.

FIG. 8 illustrates another exemplary chiller 98 that includes a heatexchanger 100 for transferring heat from refrigeration system 26 to freecooling system 28. Heat exchanger 100 is located downstream of condenser62 and may be employed when chiller 98 is operating in the third mode ofoperation. Heat exchanger 100 may receive condensed, or partiallycondensed, refrigerant from condenser 62 and may function to furthercondense and/or subcool the refrigerant by transferring heat from therefrigerant to the cooling fluid circulating within the second circuit32 of free cooling system 28.

FIG. 9 illustrates yet another exemplary chiller 102 that employs twoheat exchangers 104 and 106 that may transfer heat from refrigerationsystem 26 to the second circuit 32 of free cooling system 28. Heatexchanger 106 is located upstream of condenser 62 and may desuperheatthe compressed refrigerant exiting condenser 58. From heat exchanger106, the refrigerant may enter condenser 62, where the refrigerant maybe condensed, or partially condensed. Heat exchanger 104 is locateddownstream of condenser 62 and may further condense and/or subcool therefrigerant exiting condenser 62.

As the refrigerant flows through heat exchangers 104 and 106, therefrigerant may transfer heat to the cooling fluid within circuit 32.Chiller 102 is configured so that heat exchanger 104 receives thecooling fluid from air-to-liquid heat exchanger 42 before directing thecooling fluid to heat exchanger 106. In this manner, the relativelycooler cooling fluid may be used for subcooling the condensed, orpartially condensed, refrigerant exiting condenser 62. After the coolingfluid has been heated by flowing through heat exchanger 104, therelatively warmer cooling fluid may be used to desuperheat the highertemperature refrigerant entering condenser 62. In other embodiments,however, the chiller may be configured so heat exchanger 106 receivesthe cooling fluid before heat exchanger 104.

As described above with respect to FIG. 2, various pump and valveconfigurations may be employed within the chiller. FIG. 10 illustratesanother exemplary chiller 108 incorporating an alternate pump and valveconfiguration. A pump 110 may be disposed within part of the freecooling system that is common to the first and second circuits 30 and 32so that only one pump may be employed in free cooling system 28. Atwo-way valve 112 may be located within the second circuit 32 andanother two-way valve 114 may be located within the first circuit 30.Two-way valves 112 and 114 may be connected to control circuitry 72 toselectively direct the cooling fluid to either first circuit 30 orsecond circuit 32, depending on the mode of operation. When the systemis operating in the first or second modes of operation that employ freecooling, valves 112 and 114 may be configured to circulate cooling fluidthought the first circuit 30 as described above with respect to FIG. 2.When the system is operating in the third mode of operation to removeheat from refrigeration system 26, valves 112 and 114 may be configuredto circulate a portion of the cooling fluid within the second circuit32. Pump 110 may be disposed at the exit of air-to-liquid heat exchanger42. Of course, the locations of pump 110 and valves 112 and 114 mayvary. For example, in other embodiments, pump 110 may be located at theentrance to air-to-liquid heat exchanger 42. In another example, valve114 may be located between connection points 39 and 40. Further,additional pumps, valves, sensors, transducers, and the like may beincluded within the exemplary chiller systems described herein.

FIG. 11 illustrates yet another exemplary chiller 116 incorporating analternate pump and valve configuration that employs an expansion tank118. Expansion tank 118 is located within the second circuit 32 of freecooling system 38 and may allow for thermal expansion when a portion ofthe cooling fluid is circulated within the second circuit 32 during thethird mode of operation. Expansion tank 118 may be any suitable type oftank or vessel, and may normally include trapped gas to accommodatechanges in liquid volume. A check valve 120 is disposed within the firstcircuit 30 to prevent the cooling fluid from flowing backwards throughfree cooling system 28. As described above with respect to FIG. 2,three-way valve 38 may direct cooling fluid into free cooling system 28.During the first and second modes of operation, the cooling fluid mayflow through the first circuit 30 of free cooling system 28 as describedabove with respect to FIG. 2. During the third mode of operation, aportion of the cooling fluid may be isolated within the second circuit32 and pump 68 may be engaged to circulate the isolated cooling fluidthrough the second circuit 32 to remove heat from refrigeration system26. As the temperature changes and the cooling fluid expands orcontracts, a portion of the cooling fluid may be stored, or circulatedwithin, expansion tank 118. In other embodiments, the expansion tank maybe disposed within any portion of the second circuit 32. Further, thelocation of the valves may vary. For example, in certain embodiments, athree-way valve may be located at connection point 52 and check valve120 may be located between connection points 39 and 40.

While only certain features and embodiments of the invention have beenillustrated and described, many modifications and changes may occur tothose skilled in the art (e.g., variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters (e.g., temperatures, pressures, etc.), mounting arrangements,use of materials, colors, orientations, etc.) without materiallydeparting from the novel teachings and advantages of the subject matterrecited in the claims. The order or sequence of any process or methodsteps may be varied or re-sequenced according to alternativeembodiments. It is, therefore, to be understood that the appended claimsare intended to cover all such modifications and changes as fall withinthe true spirit of the invention. Furthermore, in an effort to provide aconcise description of the exemplary embodiments, all features of anactual implementation may not have been described (i.e., those unrelatedto the presently contemplated best mode of carrying out the invention,or those unrelated to enabling the claimed invention). It should beappreciated that in the development of any such actual implementation,as in any engineering or design project, numerous implementationspecific decisions may be made. Such a development effort might becomplex and time consuming, but would nevertheless be a routineundertaking of design, fabrication, and manufacture for those ofordinary skill having the benefit of this disclosure, without undueexperimentation.

1. A refrigeration system comprising: a free cooling system configured to exchange heat between a cooling fluid and ambient air; and a heat exchanger configured to receive refrigerant and to transfer heat from the refrigerant to the cooling fluid.
 2. The refrigeration system of claim 1, wherein the heat exchanger is disposed within a high pressure side of a vapor-compression refrigeration system.
 3. The refrigeration system of claim 1, comprising a first refrigeration system configured to implement a vapor-compression cycle with the refrigerant.
 4. The refrigeration system of claim 3, wherein the first refrigeration system comprises: a compressor configured to compress the refrigerant; a condenser configured to receive and to condense the compressed refrigerant; an expansion device configured to reduce pressure of the condensed refrigerant; and an evaporator configured to evaporate the refrigerant by absorbing heat from the cooling fluid prior to returning the refrigerant to the compressor.
 5. The refrigeration system of claim 4, wherein heat exchanger is configured to condense or subcool the refrigerant exiting the condenser or to desuperheat the compressed refrigerant prior to the refrigerant entering the condenser.
 6. The refrigeration system of claim 1, comprising an additional heat exchanger configured to receive the refrigerant and transfer heat to the cooling fluid, wherein the heat exchanger is configured to partially condense the refrigerant and the additional heat exchanger is configured to subcool the refrigerant.
 7. The refrigeration system of claim 1, wherein the free cooling system comprises an air-to-liquid heat exchanger configured to transfer heat from the cooling fluid to the ambient air.
 8. The refrigeration system of claim 1, comprising at least one valve configured selectively to bypass the free cooling system and to direct the cooling fluid to the free cooling system before the cooling fluid enters an evaporator in fluid communication with the refrigerant.
 9. The refrigeration system of claim 1, wherein the free cooling system comprises one or more valves defining a first circuit and a second circuit, and wherein the first circuit is configured to circulate the cooling fluid between a cooling loop and an air-to-liquid heat exchanger in fluid communication with the ambient air, and the second circuit is configured to circulate the cooling fluid between the heat exchanger and the air-to-liquid heat exchanger.
 10. A refrigeration system comprising: a vapor-compression refrigeration system comprising an evaporator configured to remove heat from a cooling fluid circulating through a cooling loop; a free cooling system configured to circulate the cooling fluid through a first circuit to exchange heat between the cooling fluid and ambient air without implementing a vapor-compression cycle; and a second circuit disposed in the free cooling system and configured to circulate an isolated portion of the cooling fluid through a heat exchanger common to the vapor-compression refrigeration system and the free cooling system.
 11. The refrigeration system of claim 10, wherein the refrigeration system is disposed within a common support frame.
 12. The refrigeration system of claim 10, wherein the cooling fluid comprises water, a brine solution, or a glycol solution.
 13. The refrigeration system of claim 10, wherein the vapor-compression refrigeration system includes a condenser and the heat exchanger is configured to supplement the condenser by desuperheating, subcooling, or partially condensing refrigerant flowing within the vapor-compression refrigeration system.
 14. The refrigeration system of claim 10, wherein the free cooling system includes an air-to-liquid heat exchanger configured to receive the cooling fluid from the first circuit and the second circuit and to remove heat from the cooling fluid.
 15. The refrigeration system of claim 14, wherein the vapor-compression refrigeration system includes a condenser, and wherein the condenser and the air-to-liquid heat exchanger comprise multichannel heat exchangers configured to share a common fan.
 16. The refrigeration system of claim 10, comprising a controller configured to direct the cooling fluid through the first circuit or through the second circuit based on a sensed temperature of the ambient air.
 17. The refrigeration system of claim 10, comprising one or more valves or pumps configured selectively to direct the cooling fluid through the first or second circuit.
 18. A method for operating a refrigeration system, comprising: operating a vapor-compression refrigeration system to remove heat from a cooling fluid; and circulating an isolated portion of the cooling fluid within a free cooling system to remove heat from the vapor-compression refrigeration system.
 19. The method of claim 18, comprising circulating the cooling fluid to an air-to-liquid heat exchanger within the free cooling system to remove heat from the cooling fluid.
 20. The method of claim 18, comprising selecting a mode of operation for the refrigeration system based on a sensed temperature of ambient air, wherein the circulating an isolated portion of the cooling fluid comprises a first mode of operation and wherein removing heat from the free cooling system without implementing a vapor-compression cycle comprises a second mode of operation.
 21. The method of claim 18, comprising exchanging energy between the cooling fluid and a refrigerant within the vapor-compression refrigeration system to partially condense or desuperheat the refrigerant. 